Mini Pontoon Build Along 2024

SHaugh reply :

As Discussed in this Kayak thread:

http://www.bassresource.com/bass-fishing-forums/topic/145620-kayak-fishing/page-3

I will post various instructions on how to make my mini pontoon boat:

I will keep my instructions fairly brief. But if you have questions go ahead and ask.

The first step is to build the pontoon outer covers. For that you will need to purchase 4 (edited, I forgot the carpet for the decking) of these carpets from Home Depot:

http://www.homedepot.com/s/foss%2520area%2520rug?NCNI-5

I suggest the one called Ribbed Chocolate. The ribbed texture looks best to me, and the brownish color hides water discoloration best.

This diagram shows the cuts sizes. For this boat I will assume that you will purchase solid polystyrene cylinders, so disregard any discussion of Mesh bags.

SHaugh reply :

Cut the carpet into the sizes shown. you will have room for the circles on the ends of each large cut piece. The third carpet is simply cut in half to make the 2 wraps that will secure the pontoons to the boat.... see the picture... the 4th carpet is for the deck.

OroBass reply :

Were do you buy the styrofoam

SHaugh reply :

There are lots of places to buy it.

I use these guys...

http://www.drewfoam.com/

They will sell a 21" diameter x 18" diameter block for about $22. You need 4 per pontoon.... Shipping cost is pretty high on that stuff ... so you should try to find somebody local where you can pick it up....

this is another online guy... prices are higher though...

http://univfoam.com/

you can buy this stuff from Home Depot.. and cut it up into circles:

http://www.google.com/shopping/product/1?lsf=seller:8740,store:3128122207190988578&prds=pid:984924210147033064,oid:984924210147033064&hl=en&cm_mmc=shopping-_-googleads-_-pla-_-202090244&ci_sku=202090244&ci_gpa=pla&ci_src=17588969&gclid=CNzT4pnxu8ECFUgA7AodeFkAqA

If you do this you can use the leftovers to make spacers like this. 21" diameter circles and 6" tall partial circles. stack them all up into about 18" high stacks.. use a little super 77 spray glue to hold them together. You will need 9 sheets per pontoon.

J Francho reply :

You're already pretty close to $250 in materials, not including the platform, transom, any tools, and sewing machine accessories (assuming you have one that can handle the carpet.)

This is what I'd consider about the cost of a better than entry level kick boat. Don't get me wrong, it's cool, and it's not going to sink if punctured. I bet it's heavy when soaking wet, too. Seems overly complicated for the typical person.

SHaugh reply :

If you want cheap you can fill them with empty water bottles or scrap EPS foam, I think most people would want to do it a little better...

My cost estimate for the boat would be around $390 with the solid polystyrene pontoons.

IF cost is an issue you can also use some solid polystyrene blocks and fill the gaps with scrap or empty bottles.

Whatever you do the amount of buoyancy will be way more than adequate.

SHaugh reply :

On 10/21/2014 at 3:11 AM, J Francho said:

You're already pretty close to $250 in materials, not including the platform, transom, any tools, and sewing machine accessories (assuming you have one that can handle the carpet.)

This is what I'd consider about the cost of a better than entry level kick boat. Don't get me wrong, it's cool, and it's not going to sink if punctured. I bet it's heavy when soaking wet, too. Seems overly complicated for the typical person.

It's not heavy when wet... that carpet doesn't hold much water.... it runs right out. it weighs about 45 lbs dry.. .about 50 pounds fresh out of the water. Easy to throw into a pickup.... even wet...

A Kayak is not for everybody... this gives you a very high platform that let's you use a comfortable chair... the canopy is also included in that cost... a nice feature down south in the summer...

A lot of people like the DIY nature of it... they can make it exactly how they want.... I agree it's not for everybody.... If you want easy buy a plastic bass raider..

J Francho reply :

I didn't mention a kayak, was talking about pontoons/kickboats.

SHaugh reply :

I thought a kickboat was a foot powered kayak... I'd never seen those before... but again the comfort aspects are in favor of my boat. You are sitting only inches above open water ... much different than the comfort level of this boat. I have an old office chair I modified to use on mine.. super comfortable.. super stable... Kick boats look like swimming to me...

Here's another example of a boat I made... Way more boat for $300 than a kickboat or air filled pontoon... IMO...

SHaugh reply :

Since cost seems to be a concern I will outline a generous estimate:

Carpet $76

Polystyrene $170 (Or $0 depending how much you want to spend)

Decking $25

Wood $15

railing $60 ( this is optional.. you can spend less)

Motor mount $10

Hardware/ misc $10

Sewing labor...$20 (If you need somebody to sew your pontoon covers)

Total cost $386 for the solid polystyrene model.

For a version in which you will scrounge your flotation from "free" materials $216.

J Francho reply :

Looks really good, man.

Crappiebasser reply :

I have them made from 30 plastic drums but never carpet. Seems like the water weight in the carpet would cause a lot of drag.

SHaugh reply :

The carpet behaves very well in the water... it doesn't get "very" wet... it has only a very light backing... you will need to see it to understand. It behave just like a mesh... water passes right though it...

The drag of the carpet and flat front ends is also of minimal concern... since you are only going a couple mph with a 30 lb motor it's not an issue at all..

This boat is not for a gas engine... it's also not for big rough water... it works perfectly on small lakes with small waves. Just like the other similar products on the market.

The weight of the water momentarily trapped inside the pontoons has another benefit. It makes the boat almost impossible to flip over... It's very stable....

SHaugh reply :

Here is how I built the decking on the super light version. I won't go into detail how to use Tnuts and bolts to complete this construction. But if you need help just ask me.

Plywood for the deck is usually a point of discussion. Some people insist you need Marine grade plywood. but that is too expensive for me... and hard to get in TN. I just buy good quality hardwood plywood and coat it with several thick layers of polyurethane varnish. Especially on the edges... I also use a Q tip after I drill all the holes and coat those inside edges really well. Do that and any plywood will last for years. Don't use the cheap 1/2".. get birch plywood, it's lighter and stiffer. If you are not worried as much about weight because you will use a trailer just buy 3/4" ply. Use the polyurethane on all wood parts... then paint.... will last for decades ....

Jay Ell Gee reply :

Ill tell you what, it's the most comfortable looking DIY build I have seen. Any plans to include cup holders for a cold beverage? That looks like the only thing it needs!

SHaugh reply :

yup... it pivots off the railing. Locks down with an eyebolt.. I just cut down one of the canopy fittings to get the locking sleeve... a good place to set your baits... and brew..

hoosierbass07 reply :

I'd fish from it! How much weight does it hold?

SHaugh reply :

^{I weigh 240... with battery and a heavy chair it's nowhere near capacity... My guess would be you'd need to worry if you were over 300... with solid polystyrene floats probably 400 lbs...}

SHaugh reply :

When you have your plywood and footpads for the railings lay out all your holes and drill... holes should be 5/16" all around.

SHaugh reply :

Once you have your boards cut and drilled use a small roller and cover everything with a couple thick coats of polyurethane varnish.. pay special attention to the edges and use a Q tip to do inside all the holes. Let it dry for a day.

Next pound in your T-nuts. They will all go into the deck plywood. Note in the drawing above.. some go on the top.. some on the bottom..

Once you have all your wood varnished and the T nuts in give it a good coat of paint. I just use latex house paint.. but you can use oil based if you like.

Test fit all your pieces once more to be sure you got it right. Next step is to carpet the deck.

Scratch a little outdoor carpet glue on the top surface:

Then line up your piece of carpet... make the ribs run front to back. check to be sure it's nice and straight.. otherwise it will look bad with carpet lines running at an angle...

Next using a staple gun.. ( a hand powered gun will work fine) ... staple the carpet with about a 3" wrap on the bottom:

Notch out where your T-nuts are.

SHaugh reply :

On the top surface use an old soldering iron to melt a hole in the carpet for the footpads.

WillJ reply :

I don"t know if I'd like casting frequently off this, but it'd be relaxing to bait fish off of for sure. On a contraption such as this a cold brew is only necessary. This is cool though.

buzzed bait reply :

more engineering than my brain is capable of!!

only question i have is how do you transport it and how much time does it take to set it up at the ramp?

SHaugh reply :

On 10/23/2014 at 12:29 AM, WillJ said:
I don"t know if I'd like casting frequently off this, but it'd be relaxing to bait fish off of for sure. On a contraption such as this a cold brew is only necessary. This is cool though.

The way I made the canopy you have more than 180 degrees in front of you... If you need to cast straight overhead just leave the canopy off that day.... unscrews by hand with a couple eye bolts.

SHaugh reply :

On 10/23/2014 at 12:48 AM, buzzed bait said:

more engineering than my brain is capable of!!

only question i have is how do you transport it and how much time does it take to set it up at the ramp?

Fits in the back of my short bed pickup perfectly with the gate closed..only takes a minute or 2.... back down the ramp, pull it off.... put the canopy on.. attach the motor.. grab the chair battery and gear.... less time than launching a trailered boat...

buzzed bait reply :

was just curious....

i had an inflatable and hated how long it took me to set it up/take it down (which really wasn't even all that long, i'm just impatient). now i have a kayak, just drop it out of the truck bed and go!

nice engineering on your rig though....

SHaugh reply :

I had a kayak for a while... Not exactly the right rig for a bigger guy.... I also didn't like how low I was to the water... I like to look down and see what's in there.... in a yak I felt a little blind...

Same with an inflatable pontoon... too low.. too uncomfortable in the seat..... too much of a feeling like I was about to go swimming...

The construction talent needed for this boat is pretty minimal.... once you see how to do it I bet almost anybody could pull it off...

Not_Here reply :

my suggestion if you have room for the prop to rotate inbetween the toons is to take the single bolt out of the TM head, turn the head around and rebolt so you have a bow mount, much better to control...extend the TM wires so you can put the battery what is currently the front to help balance weight out...leave the oars in the water so when you move they will lay to the side and cut the water which will greatly help with tracking...since oars are a secondary/back up use...i'd make hangers for them so they stay to the side and in the position you need them to be with being in the water enough to act as rudders...

SHaugh reply :

On 10/23/2014 at 1:44 AM, Frog Turds said:
my suggestion if you have room for the prop to rotate inbetween the toons is to take the single bolt out of the TM head, turn the head around and rebolt so you have a bow mount, much better to control...extend the TM wires so you can put the battery what is currently the front to help balance weight out...leave the oars in the water so when you move they will lay to the side and cut the water which will greatly help with tracking...since oars are a secondary/back up use...i'd make hangers for them so they stay to the side and in the position you need them to be with being in the water enough to act as rudders...

yup... you could convert it to a bow mount easy enough...just duplicate the motor mount holes in front and back.. then you could easily switch it over... just be sure the height is set to clear the bottom of the toons... I run it in reverse quite often... Tracking doesn't seem to be a problem even without the oars.

A nice part about this size boat is the maneuverability... it's a zero turn radius and so easy to figure 8 all over when I'm in a trolling mood...

Not_Here reply :

mine tracks spot on perfectly with how i have it now as i described to you with hangers in conjunction with the oar locks, before tracking mediocre especially in wind...just keep it in mind that it would be much improved setting it up how i mentioned...

my toon is wide enough down the center that doesn't matter how high i have the TM it clears the toons...which i have it set it up higher so i can easily reach it standing...

SHaugh reply :

Next step is to add the wraps that will hold the pontoons on to the deck. Use a double row of staples to connect the 47" wide side of the wrap to the bottom of the poplar board.. then bolt the poplar boards to the outside edges of the deck. When you get done it should look like this:

Then lay your pontoons on the underside of the decking one at a time... make sure they are centered front to back. These images from a different boat are clearer:

measure and cut the wrap so that it's nice and tight around the pontoon. Then staple it to the other poplar board.. with double staples. When you get done it should be a little short... so that when you tighten the bolts it cinches up a little. See the photo below:

When you have both pontoons mounted flip it over and start working on how you want the railings...

That should be all you need. If you have any questions just ask... ok to PM me too...

Bomber7 reply :

you got any pictures of that thing on the water and how it sits, handles in the water? Pretty neat set up

SHaugh reply :

Sorry, not many action pics... It's hard to get those on a 1 man boat..... Water comes up to a little less than the half way mark on the pontoon. With a 30 lb electric motor it moves about as fast as a 12ft johnboat. Very maneuverable because it's so short.

J Francho reply :

Christen her, "Archie Bunker's Sofa"! Looks good. Time for fish catch selfies!

Snakehead Whisperer reply :

Now all you need is to throw a La-Z-Boy on that rig. Don't forget the ottoman, although the tackle box will work in a pinch.

Seriously though, nice setup.

SHaugh reply :

I did that on my larger boat a couple times... a nice shady spot in the middle of a lake can't be beat.... You can make a boat like this with 4 of the same pontoons.

SHaugh reply :

made some fun boats as well... This one always got a reaction...

SHaugh reply :

Worked good though..

RyneB reply :

this is just awesome. If club rules allowed me, and I owned one of these, id totally fish a club tourney on one of our smaller waters with this thing.

SHaugh reply :

Here's the latest version. I made this with just square cut sheets of insulation. Easier than round and cheaper. Fill for these 2 pontoons only cost about $50 on craigslist. A little more sewing but still very easy.. even lighter for my old back..... If anybody wants more info let me know...

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Mini Pontoon Build Along 2024

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